Forklift truck batteries are one of the most expensive components of a forklift truck, making correct maintenance crucial for extending their lifespan, reducing costs and enhancing operator safety. This blog provides essential advice on how to get the most out of your forklift truck batteries through effective maintenance.
Why keep your forklift truck batteries topped up?
Safety should always be the top priority. Regularly topping up your forklift truck batteries helps maintain the correct dilution of the sulphuric acid mix, allowing the battery to reach its rated power capacity and charge without overheating or burning out. This practice not only ensures optimal performance but also enhances the longevity of your batteries.
How to top up your forklift truck batteries
- Forklift truck batteries contain diluted sulphuric acid, so wearing appropriate personal protective equipment (PPE), such as goggles and gloves, is vital when inspecting and topping up the battery cells. Using PPE protects you and those around you from potential hazards.
- Charging a lead-acid battery generates heat during the “gassing stage,” causing the electrolyte levels to rise. Therefore, it is essential to wait until the battery has cooled to room temperature before performing any maintenance.
- Always top up your battery with clean, distilled water after charging. Never top it up before charging begins.
- Avoid "over topping." This occurs when discharged forklift truck batteries are overfilled or when cells are filled beyond the manufacturer’s recommended level. Over topping can lead to excess fluid discharge and the formation of a white or yellow residue on the cell tops due to evaporated sulphuric acid. This not only presents a significant health and safety risk but can also compromise forklift performance by damaging cell links and the battery tank.
- At the same time, be mindful of “under topping.” This happens when the electrolyte level drops below the plates in the cells, reducing the battery’s performance. Insufficient electrolyte can cause damage to the cell plates, leading to reduced battery life and impaired performance. To prevent these issues, perform maintenance only on fully charged and cooled forklift truck batteries.
How often should you top up your forklift truck batteries?
How often a forklift battery needs topping up depends on several factors, including the battery’s age, quality, technology, operating temperature and usage patterns. Modern forklift truck batteries often come equipped with built-in electrolyte indicators that alert you when topping up is required.
To maintain optimal electrolyte levels, it is advisable to perform periodic checks or establish a regular schedule for battery maintenance, ensuring all forklifts are checked weekly or monthly — depending on their usage.
Key considerations when monitoring forklift truck battery health
Regular monitoring and timely action are key to maintaining the health of your forklift truck batteries. Essential maintenance tasks include keeping the cells topped up to the recommended level, checking the Specific Gravity (SG) of the acid, and ensuring cell tops and links are clean and free of residue. A fully charged and healthy battery should have an SG of around 1.265, whereas a discharged battery will have an SG closer to 1.15 and should be charged as soon as possible.
Monitoring the SG of your charged forklift truck batteries provides a good indication of their health. While a slight drop in SG over time is normal, any rapid decrease may signal an issue that needs to be addressed immediately.
For more detailed advice on maintaining your forklift truck batteries, contact our battery care team at 0370 850 1402 or fill out the contact form linked below.
